Method of kiln setting and burning



G. E. LUCE.

METHOD OF KILN SETTING AND BURNING.

Patented Feb. 22,1921.

APPLICATION FILED MAR- 27, I919.

G. E. LUCE.

METHOD OF KILN SETTING AND BURNING.

Patented Feb. 22, 921.

3 SHEETS-SHEET 2.

APPLICATION FILED MAR-'27, I919.

"G. E. LUCE. METHOD- OF KILNISETTING AND BURNINVGX 'AP'PLICATION Fl[.ED "ML 27. 919.

PatentedEeb. 22, 1921.

' 3 SHEETS-SHEET 3.

GRAFTON E. Loon, or CHICAGO, ILLINOIS.

METHOD on Kim: sn'r'rnve AND BURNIivG.

weaves.

Specification of Letters Patent.

' Patented Feb. 22, 1 921.

Application filed March 27, 1919. Serial No. 285,603.

To all whom "it may concern Be it known that I, GRAFTON E. Loon, a citizen of the United States, and a resident of Chicago, Illinois, (whose post-office address is No. 14:0 North Pine avenue, Chicago, Illinois,) have invented an Improvement in Methods of Kiln Setting and Burning, of.

which the following description, in connection with the accompanying drawings, is a specification, like letters on the drawings representing like parts.

My present invention relates to the set-' ting of kilns for burning brick, tile and other clay products andto the method of burning a kiln thus especially set. In carrying out my invention, I contemplate the building or setting of the kiln, with'one or more relatively tightly set courses brick and at predetermined heights or levels throughout the kiln. Preferably where a plurality of such tight courses are employed, I prefer to utilize a graduated spacing or setting of the successive tight courses, using such variations in the spacing as has been found advisable in practice. lVith the special object in view of burning the kiln by my improved and novel process, I contemplate thesetting of a standard sized kiln, for example, a kiln fifty six brick wide or approximately thirty eight feet and forty eight brick, or about fifteen feet high and of thirty arches or one hundred twenty feet in length, more or less, with these ti ht courses, including the topmost platting, thus dividing the kiln into five horizontal zones or strata; This division is, of course for illustrative purooses only and varying sized brick and difierent bodies of clay may require variations in the number and setting of the tight courses to carry out my invention. This method of building or setting a kiln can be readily carried out either by hand or by means of mechanical setters, and the desired tightened course or coursescan be quickly arranged by simply filling in an additional numberof brick on the desired course in addition to the brick already set therein. Y'Jhere a mechanical setter is employed, the topmost course could be that selected for the closer setting in the units by which the kiln is built and thus my no vel type of kiln and the method of building the same can be readily set by mechanical means.

The object of setting a kiln as above briefly outlined, with one or more tightened courses at predetermined levels and pref erably ingraduated degrees of tightness throughout the kiln is primarily to facilitate and to automatically control the burning, My improved burning process is a distinctly novel method and enables the burningproc- 1 ess to be applied to the especially set type of kiln which I have devised. 7

Because of the several tightened courses of brick, I provide predetermined means to choke or hold' the pressure and heat within.

the kiln'between such tightened course and the fire, as will be more fully explained hereafter. I also prefer to entirely eliminate the danger of, choking the kiln by steam and to rely mainly upon the tightened courses for the several steps in the burning process rather than upon any such uncertain tightening or' choking as'that given by escaping steam. To this end, I prefer to first water smoke the entire kiln and for this-purpose also I- have discovered that the tight'end course of brick is important In order to effect the water smoke preliminary drying of the kiln, a relatively low fire is first supplied for the requisite number of hours to the arches. In fact, due to the first tightened course of brick above thefiring arches, it is substantiallyg impossible to maintain any large degree of heat or fire as there is not enough draft through the kiln for this purpose. The tight course therefore compels the operation of first water smoking and eliminates all danger of the kiln running away with itself? or getting hot enough to damage the product at any, point. I believe that this method of utilizing a course of brick set relatively on or a plurality of such tightly set coursesas means cooperating with the burning'of the kiln,to be adistinct novelty in this art and I wish to claim the same broadly,

Heretofore it has been attempted to burn Zkilns of brick by first choking the kiln through the super-abundant supply'of steam generated by a'relatively high and intense heat applied to the kiln from the beginning oftheburning. I This prior method of choking a kiln relied upon the evaporation of water or moisture from the green'brick faster than the draft of the kiln could possibly carry it away, thus forming a damper or blanket of steam. Such choking, however, wasnecessarily indefinitev in position, location, time, and extent and the densityof this blanket of steam necessitated a rela- V tive intense fire greater than the green brick could properly stand thereby damaging the product. Nor was there any possibility of effecting such a choking by steamat successive or at predetermined points throughout the kiln. My present invention obviates the difliculties and uncertainties heretofore experienced with such prior method, and I rely upon a positive, predetermined and definite means to choke the kiln at such plurality of points, as desired. I find that three elements are capable of being utilized in thus choking the draft through the tightened course of brick, viz. the decreased spacing in the setting, the friction of the draft due to the difficulty of initiating the draft through moist brick and the natural choking at this tightened course, as the air expands and the heat increases in the kiln below it. By thus predetermining the height and extent of the portion of the kilnto be burned, I am enabled to accomplish the very important results of quickly and easily raising and maintaining the desired pressure in this particular portion, section or zone of thekiln and also very greatly conserving fuel, only enough heat and pressure'to burn that section of the kiln under the tightened course being required. Thus in burning the brick kiln under thefirst tightened course above the arches, for example, after the kiln has been water smoked, the heat and pressure. are supplied and maintained in this lowermost zone or sectionthe proper heat to burn the brick weatherproof and shrink them to normal size, and the tightened course being the topmost of the brick in this section being burned are the last to be vitrified or fused and to shrink, necessarily aided inholding the pressure and heat, choking the kiln up to this course until it is shrunk. Thereupon with the shrinking of this tightened course, the pressure in the section below it is automatically released and the draft and heat passes through into the section above, to be again choked by the next succeeding tightened course. lVhereupon the further supply of heat and pressureto the kiln raises the pressure and the heat in the section under the next tightened course until this portion or section of the maintaining the pressure; eliminating the danger of other burning and greatly conserving fuel because only heat and pressure substantially sufficient for the burning of one section at a time are supplied. By retaining all the heat in the arches from escaping excepting as the successive sections are burned, the heat supply is thus forced to its highest efficiency and the setting of the kiln is spaced just sufficiently for the escape of fuel gases. As each tightened course of dried brick is burned, shrinking and enlarging the openings, a pronounced draft is exerted from the arches so that the operators can keep track of these successive stages-in the burning, a pressure and draft being released from one-section up into the next one not only by the shrinking of the brick,.but also through the easier flow of heat pastthe now dried and burned brick, a'dried brick offering much less friction than a wet or moist brick to the passage of such heat and gases.

lieferring to the drawings illustrating in diagrammatic form my present burning process and showing. a kiln embodying the invention;-

Figure l trating a 16-arch .kiln of standard type;

Fig. 2 is an enlarged view on the line 2-2 is a view in perspective illusof Fig. 1 illustrating the methodof setting a the kiln with a. plurality of tight courses therein; 7

And Fig. 3 is a fragmentary cross sectional view on the line 33 ofFig. 1.

As shown in Fig. 1, a kiln of typical field type, is shown adapted for burning with oil, gas, or powdered coal wherein the sides are scoved or walled as usual. This has the usual construction of arches (2) which as shown in Fig. l. are built out slightly to dog houses, 3 to facilitate the use of the burners for oil, gas, powdered coal. or the like. The kiln maybe setas is customary throughout the first benches and to a height siulicient or appropriate forthe first or lowermost section or use, whereupon tightly et or closer spaced course of'brick is set.

As shown in the drawings, this tighter course N o. .5, is the sixteenth course from the bottem and this setting is preferably nineteen over six, the normal setting up to the sixteenth course being shown as six over two brick. Thereupon the succeeding courses or units may be set with the usual spacing but preferably as shown ,---it being understood that I contemplate employing any desired mechanical setter for building the kiln and setting all courses, theirela tively tight or closer set courses being formed simply by filling in the'extra brick noted by hanc or ti htening the courses as desired. This next unit may also be of lib course, the twenty-fourth course from the bottom, setting this course still closer than the first course 5, viz., sixteen over five. The next tightened course is shown as at the thirty second row, No. 7 in the drawings and set thirteen over four. A tightened course 8 set at the fortieth course is formed in the proportions of ten over three and the topmost courses 9 are preferably formed With the platting as closers, as seven over two, thus just allowing spaces or vents for the water smoking and the escape of foul gases.

While I prefer to employ a successively tightened series of courses at predetermined points throughout the height of the kiln, as just explained, it will be understood that I am not thus limited and also that the tightened courses may be otherwise set or formed. One of the objects and advantages of having the tightened courses substantially increasing as shown in the drawings and as above explained is to provide a series of tight courses proportional to the volume of heat, draft, and burning to be carried out in the kiln. Thus as the lower portions, for example, the first two sections of the kiln have become burned, there is a greater volume of heat and force and consequently a slightly tighter setting for the tightened course No. 7, at the thirty second row to produce substantially the same result of holding in the pressure and heat until the shrinkage and burning of this course and releasing of pressure and heat to the next above section. Consequently I consider it advisable to have the spacing in successively tightened courses gradually lessened, approximately proportional to the gradual increasing volume' of heat and pressure. As the mass and volume of heat increases, the

pressure also necessarily increases within the kiln and in order to obtain substantially the same restraint and within the varying tightened courses, the graduated method or setting the same is preferable. c

I- find that in actual practice, my novel method of burning of this new type of kiln is carried outsubstantially automatically. As already explained, it is practically impossible, at the first portion of the burning, to supply any more fuel than sufficient to water smoke the kiln. As soon as the kiln has been water smoked and is relatively dry,

6 thereabove. Upon this release of pressure in the lower section, whenburned, and the raising of the heat into the second portion, the fires in the arches will be stimulated by this increasing draft and the burners will at once know that the first portion has been burned through. Accordingly the fires are increasedto supply the heat and pressure necessary'for burning the second portion used to burn the brick. I prefer to set the v platting'as best shown at 10, Fig. 2 showing a course of burned brick set edgeW-ise instead of otherwise and fast with the last course 9 of green brick. This can be readily accomplished when setting the kiln and each course is trued up with the other by-a spade, shovel, or the like. Furthermore this method of platting enables me'to set the same on the car when utilizing a mechanical setter and applying this platting to the topmost units in the kiln. As a matter of fact, the method of platting just described and shown gives a much tighter topmost roof to the kiln than that of ordinary setting, since the greatly increased length of the small vents through the topmost course increases the friction of passing heat, retainingthe same within the kiln. I

While I have described .the method of utilizing a tightened course ofbrick and preferably :a series ofti htened courses, it will be appreciated that f do not limit this proc-" ess to the burning of brick, as other clay products may be made and'burned in this manner with equal advantage, nor do I limit the process to the type of kiln shown in the drawings. Furthermore as long as the tightened courses intercept'the line of travel ofthe heat and gases, I may form the same. horizontally, vertically, or otherwise and carry out the object and purpose of my invention andattain the advantages and result incident thereto. a p My present invention isfurther described and defined in the formof jclaims as follows 1. Themethod of setting a kiln which consists in dividing it into" a plurality of horizontal portions adapted to be burned successively, the dividing means having provision for automatically changing as the burning progresses.

2. The method of setting a kiln which consists in dividing it into a plurality of horizontal. portions adapted to be burned successively, the dividing means having provision for automatically changingfrom a dividing to a conducting means as the burning progresses. i i r 3. The method of setting a kilnwhich consists in dividing it into a plurality of horizontal portions adapted to be burned successively, the dividing means having provision for automatically changing proportionately to the progress of the burning.

4. The method of setting akiln which consists in dividing it into a plurality of horizontal portions adapted to be-successively burned by setting courses of brick with a different spacing from that of the kiln.

5. The method of setting a kiln which consists in dividing it into a plurality of horizontal portions adapted to be successively burned by setting courses of brick with a different spacing from that of the kiln, at a plurality of predetermined positions in the kiln.

6. The process of setting akiln which consists informing a plurality of divisions across the line of travel of the gases during burning. the dividing means consisting in a course of brick setting closer than the normal brick setting in the kiln, said dividing course being'spaced sufliciently to permit a flow of gas and heat therethrough.

7. The process of setting a kiln which consists in forming a plurality of divisions across the line of travel'of the gases during burning, the dividing means consisting in a course .of brick setting closer than the normal brick setting in the kiln, successively tight courses being differently spaced.

8. The process of setting a kiln to control the burning which consists in setting a plurality of courses of brick relatively closely spaced to constitute means to retain heat and pressure in portions of the kiln adapted to be burned successively, said courses belng so spaced as to permit the flow of heatand pressure therethrough upon burning andshrinking of the brick in-said tight courses.

thereby.

11.,A kiln adapted to be burned, having a plurality of separate courses of brick dividing the kiln, said courses being set in equal gradually .decreasing spacing from the bottom of the kiln to the top.

12. A kiln of brick to be burned having a plurality of courses of brick set relatively tighter and in different spacing than that of the normal setting of the brick, comprising one course in the proportion of nineteen brick over six, a course in the proportion of sixteen over five, and of thirteen over four, ten brick overv three, and seven brick over two brick, said courses being'spaced itrom each.

other to divide the kiln into burning portions.

13. A kiln of brick to be burned having a plurality of courses of brick set relatively tighter and in different spacing than that of the normal setting of the brick, comprising one course 111 the proportion of nineteen V brick over six, a course in the proportion of sixteen over live, and of thirteen over four, ten brick over three, and seven-brick over two brick, said spaced courses being proportionfire at the beginning of the burning, then supplying heat sufiicient partly to burn that portion of the kiln between the arches and the relatively tight course until the said portion and said course of brick are suliiciently burned to release the heat and pressurethrough the said tightcourse to the next portion of thekiln, then supplying heat sufficient to bring the second portion to a burning temperature and so on. a

15. The process of: burning clay products which consists in setting same in a kiln with a plurality of heat and pressure retaining courses in the kiln extending horizontally across the line 01' travel of the heated'gases thus adapting the kiln to be burned in successive portions, thenv supplying heat for drying the kiln, then supplying heat sulficient to vitrify or fuse-the brick in the first portion adjacent the arches and maintaining heat and pressure therein until the dividing course of brick isi sufliciently burned to shrink to release the heat and pressure into the next ad acent portlon, then raising the heat to supply a fusing temperature to; the

' second ortion until the course dividin the second portion. from the unburned part is suflicientlyburned and shrunk to again re lease the volume of heat and pressure to the succeeding portion of the kiln and so on progressively until all are burned.

16. Theprocess of burning clay artioles which consists in "setting the same in a kiln "with provision for" dividing the 'kiln into a plurality of portions horizontally across the line of travel of the heat and gases, supplying a drying heat to the kiln and then supplying heat under 7 pressure to bring the clay products into the first divided portion up to portions of the kiln the required heat for vitrifying or fusing and maintaining the same under sufficient pres sure to force the heat into the brick in that portion, then during the progress of the burning When the pressure is released from 10 pressure for the burning and so on propressively until the kiln is completely burned.

In testimony whereof, I have signed my name to this specification, in the presence of two subscribing Witnesses.

' GRAFTON E. LUCE. Witnesses:

JAMES R. HQDDER, RACHAEL L. CLARK. 

